Case Studies

U.S. Army Common Base Shelters

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Specialist Services has successfully completed the 20’ x 8’ 3-1 Expandable Shelters for US Army project

The US Army’s 405th Army Field Support Brigade Tele-Maintenance and Distribution Cell-Ukraine (TDC-U) selected Specialist Services, a Centurion company, to provide 3-1 expandable shelters to support their mission.

When deployed, each ISO container-based expandable shelter provides 475sqft of usable internal space and is complete with small power, data and comms. The shelters were configured to facilitate the sustainment of weapon systems being operated on the frontline in Ukraine, via remote, encrypted communication systems.

As an urgent operational requirement, we manufactured and delivered seven units in only seven weeks.

Key Features

  • ISO 668 1CC size (20’ x 8’)
  • 3-1 (double-sided) expandable shelters
  • Air transportable
  • 15-minute set up time
  • 400V 50Hz
  • 24,000 BTU heating / cooling
  • Levelling jacks

U.S. Air Force Mobile Guard Houses

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Specialist Services has successfully completed the Ballistically Protected Guard Houses project

The U.S. Air Force Europe’s 48th Security Forces Squadron based at RAF Lakenheath, United Kingdom, selected Specialist Services, a Centurion company, to deliver twenty-two ballistically protected mobile guard houses.

Each defensive position includes a 1.5m x 1.5m guard cabin, specially designed to be capable of withstanding armor-piercing ammunition. They feature defensive ring ports offering 360-degree coverage, integrated security spot lighting, and a trailer for easy deployment throughout the installation.

These units are designed to elevate the 48 SFS defensive capabilities and effectiveness, ensuring they can more safely fulfil their role as the integrated base defense force for the installation.

Key Features

  • 1.5m x 1.5m x 2.3m
  • NIJ Level IV ballistic protection
  • 4# viewing windows
  • 8# weapon ports
  • Integrated folding steps for elevated mounting locations
  • 360° spot light coverage
  • Holding down positions for trailer

U.S. Air Force Deployable Field Armory

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Specialist Services has successfully completed the 13’ x 8’ x 8’ Deployable Field Armory project

The U.S. Air Force’s 33rd Rescue Squadron based at Kadena Air Base, Japan, selected Specialist Services, a Centurion company, to supply a deployable field armory.

The armory is constructed of ¼” steel and proprietary security panels that provide secure storage for up to 200 weapons and associated equipment. The armory is complete with environmental controls, including air conditioning and dehumidifying, exterior weapon mounts and maintenance tables, and a NAPEC rated security HASP.

The armory is highly mobile and has a tare weight of only 9000lb, which
enables deployment via C-130 or MTVR.

Key Features

  • 13’ x 8’ x 8’
  • LPS 1175 SR3 security rating
  • 9000lb tare weight
  • C-130 and MTVR Transportable
  • Exterior weapon mounts for maintenance
  • Integrated environmental controls
  • Flexible weapon racks

Secure Working Environments

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Specialist Services has successfully completed the 10’ x 8’ x 8’6” Secure Working Environments project

The United Nations awarded Specialist Services, a Centurion company, a contract to provide four 10’ x 8’ ballistically protected secure working environments.

The ISO container-based units serve as cashier’s offices and support the United Nation’s Multi-dimensional Integrated Stabilization Mission in the Central African Republic.

Meticulously designed for enhanced security and functionality, the units are set to play a critical role in humanitarian operations. The ballistically-protected design ensures the safety of aid workers and the secure distribution of essential supplies in regions with elevated risk profiles.

Key Features

  • 10’ x 8’ x 8’6” ISO Containers
  • NIJ Level III ballistic protection
  • Document transaction drawer
  • Secure vestibule
  • Two workstations
  • Internal cash safe
  • Integrated HVAC
  • 360° security camera coverage

RF Shielded Deployable Magazine

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Specialist Services has successfully completed the 20′ x 8′ RF Shielded Deployable Magazine project

Specialist Services, a Centurion company, was contracted to manufacture and deliver a 20’ x 8’ deployable magazine to a NATO country. The magazine was designed to comply with multiple international standards and specifications including CFR 555.208, DOD’s Manual 4145, 26M, ER 2014, and ATEX.

The magazine was complete with electromagnetic protection at 25dB in the 1 to 12 GHz range, external motion sensor light, internal Ex lighting, lighten-ing protection, a high security door, integrated access ramp, and bullet-resis-tant external envelope.

The unit can be deployed by commercial or military transportation including RMMV HX or MAN EPLS.

Key Features

  • ISO 668 1CC size (20’ x 8’)
  • CSC Certified
  • CE Marked
  • 27 CFR 555.208 Bullet-Resistant Design
  • 25dB at 1-12GHz Electromagnetic Shielding
  • Ex Lighting

70-Man LQ Complex for Sapura Energy

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Specialist Services, a Centurion company, successfully completed a 70-Man Living Quarters Complex for Pegaga Development Project

Sapura Energy awarded Specialist Services an EPCC (Engineering, Procurement, Construction and Commissioning) contract for a 70-Man Modular Living Quarters Complex for Mubadala Petroleum, for the Pegaga Gas Field Project in Malaysia.

Project: 70-Man Living Quarters Complex for Pegaga Development Project
Client: Sapura Energy
End User: Mubadala Petroleum
Location: Block SK320 offshore Sarawak, Malaysia
Project Completion: June 2021

Project requirements

Sapura Energy required a complete turnkey solution for a 70-man living quarters (LQ) complex to be installed on their platform, including design, engineering, procurement, construction, outfitting, installation of equipment, third party approvals, testing and pre-commissioning. The Pegaga Development Project consists of a manned Integrated Central Processing Platform (IPCC), where the LQ needed to be integrated. Based on decades of experience, expertise and track record in providing turnkey LQ projects, in October 2018 the Client awarded the project to Specialist Services.

Solution

This permanent offshore 70-man LQ project was executed in modular construction, in lieu of the conventional stick-build construction method. Optimising the size of the modules during engineering offered the full benefits of offsite fabrication, lower shipping costs as well as integration resources required onsite.

The project involved interface between Sapura Energy and Mubadala Petroleum in Malaysia, and Specialist Services teams based in Dubai, India and Singapore, on engineering, project management, techno-commercial, transportation, installation and delivery support.

With total dimensions of 39.16m x 11.8m x 19m, the LQ was constructed in 4 levels and with a helideck on the top.

Conclusion

The modules were completed and shipped in Q2 of 2020 amidst the restrictions during the pandemic. The situation affected the overall subsequent installation schedule at site in Malaysia, especially due to mobilization of personnel required for the supervision, as well as Client’s own overall installation schedule.

 

 

 

 

 

 

 

From commercial and technical negotiations to contract award in October 2018, from engineering to completion of modules in 2019 and 2020, and from the supervision at site in Malaysia during a pandemic to the project completion – this project involved extraordinary coordination and efforts by the different teams to complete this full turnkey modular LQ project.

Modular Building Refurbishment for ExLog

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Specialist Services successfully completed the Refurbishment works of a 27ft modular building for ExLog

In October 2019, ExLog awarded Specialist Services the Refurbishment works for one of their 27ft modular buildings manufactured in 1998.

Client: ExLog
End User: ExLog
Location: Abu Dhabi, UAE
Project Completion: January 2020

Project requirements

In August 2019, ExLog sent a requirement to Specialist Services for refurbishment works of a 27ft Zone II certified modular building and then awarded the project in October 2019, with a project timeline of 10 weeks. The unit was manufactured in 1998 by Labtech Services Limited in the UK, a Specialist Services Group Company since 2011.

The full scope of work was determined following a visual survey of the unit by a Specialist Services Engineer, which included the following:

  • Full external blasting and painting
  • Supply and installation of new logos
  • Supply and replacement of A60 door lock, door hinges and seal
  • Supply and installation of door closer
  • Repairs of B15 door and replacement of gasket
  • Repairs of Sink and cleaning of rested area
  • Supply and installation of window glass and repairs of frame
  • Replacement of emergency door lock and handle
  • Cleaning of emergency door rested area
  • Supply and replacement of drawer locks
  • Painting of metallic rusted drawers
  • MPI to be carried out by a third party along with inspection
  • Sling recertification
  • Replacement of MCT blocks
  • Complete testing of electrical and pressurisation system
  • Complete servicing of A/C system

Solution

Following the cabin delivery at the Specialist Services yard, after systems’ power on, a number of other required repairs have been identified. These included the failure of various A/C system components, fire & gas detection devices, and other areas. In addition, during the blasting and painting process, we identified further structural issues, which resulted in the required replacement of the A60 main door and emergency escape hatch.

Within the tight timeline, we worked closely with the Client for the additional works requirements, sourcing all additional material, and delivering the refurbished unit within the agreed deadline. The project has been completed in line with all the requirements and specifications.

Conclusion

The Client was very satisfied with the quality of our Refurbishment works, and with our project management skills used in the completion of all additional replacements and repairs without any delays. As a result, ExLog extended the order to carry out a variety of refurbishment works on four modular buildings. The refurbished unit is now being used by ExLog in Abu Dhabi, UAE.

Modular Firing Range

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CoverSix Shooting Training Range interior

Specialist Services has successfully completed a 2-lane x 15m Modular Firing Range project

CoverSix Shooting-Training RangeSpecialist Services were awarded a contract to design, manufacture, install and commission a 2-lane x 15m Modular Firing Range.

Project: Modular Firing Range
Client: Confidential
End User: Confidential
Location: Abu Dhabi, United Arab Emirates
Project Completion: November 2019

Project Requirements

Specialist Services were awarded the project for the design and manufacture of a modular firing range with the following specifications:

  • 2 firing positions (lanes)
  • 15m firing distance
  • 100% ballistic containment with a Zero Surface Danger Zone
  • 100% fresh air ventilation system
  • Overhead retrievable targetry
  • Bullet Trap
  • Integration of judgemental / use-of-force simulation for laser and live fire training
  • Integration of visual and audio effects systems to create an immersive training environment

Solution

Specialist Services proposed a Modular Firing Range (MFR), fully compliant with the specifications and requirements provided from the Client. The MFR consists of two (2) CSC certified modules, joined to create a 100% ballistically-contained indoor firing range, capable of supporting both static and tactical training exercises.

CoverSix Shooting Range Ballistic ContainmentBallistic Containment

To ensure ballistic containment of the MFR, we utilized proven and successfully tested techniques, material, and equipment, which provide 360° ballistic containment with a zero surface and vertical danger zone (SDZ/VDZ). This was achieved through lining the interior walls, floor and ceiling with 12mm thick SSAB Hardox AR500 steel plates. We combined these with BSW Regupol E43 shredded rubber tiles, which were offset from the steel plate to prevent ricochet or backsplash towards the origin of fire, even in the event of a negligent discharge.

CoverSix Shooting Range Bullet TrapBullet Trap

The Client opted for a Granulated Rubber Bullet Trap, which is located directly behind the 15m target position, to capture the majority of rounds fired downrange. The bullet trap consists of a mild steel frame supporting a sheet steel platform, with a thick layer of rubber granules placed on top of the platform. The rubber granules provide a 60cm thick layer on the platform, which is positioned at an angle of 37 degrees. Due to the layer of rubber granulate, when rounds are fired into it, the friction between the granules and the rounds decelerates the rounds, bringing them to a complete stop.

CoverSix Shooting Range TargetryTargetry

Each of the MRF’s firing positions includes an overhead retrievable target. To enhance training value, the targets move 15 meters downrange, can be programmed to stop on time or in a preloaded scenario, and stop or move with intervals of 1m. To help create an immersive training environment, the targets also have back and front lighting, strobe and distraction lighting.

Air Conditioning and Mechanical Ventilation

A key component of the MRF is the Air-Conditioning and Mechanical Ventilation (ACMV) system. The MFR was delivered with a pre-packaged and fabricated ACMV system, designed to ensure a minimum airspeed of 0.38m/s at 1.5m above finish floor level, and a laminar airflow along the length of the range with no eddies or backflow of ventilation air allowed. To comply with environmental regulations and best practices, the ACMV system was fitted with a three (3) stage filter system for the exhaust air. The system consists of MERV 6 – 2″ pleated pre-filters, MERV 14 stiff pocket bag filters, and high-efficiency particulate air (HEPA) 99.97% at 0.3- micron filters, ensuring that all contaminants and toxins generated during firing are not discharged into the atmosphere.

Conclusion

CoverSix Shooting Training Range interior

CoverSix Shooting Training Range exterior

CoverSix Shooting Range Interior lighting

 

 

 

 

 

The MFR was delivered and successfully installed on the Client’s site in October 2019. Commissioning was undertaken in conjunction with the Client and the MFR was declared fully operational in early November 2019.

Reinstatement and Modification of Portable Accommodation Modules for Sea Trucks Group

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Reinstatement and Modification of Portable Accommodation Modules for Sea Trucks Group

In November 2016, Sea Trucks Group (STG) awarded Specialist Services the contract for the reinstatement and modification of the Accommodation Modules built for STG in 2014, to form a block 11 modules wide and 4 modules high.

Project: Reinstatement and Modification of Portable Accommodation Modules
Client: Sea Trucks Group
End User: INPEX
Location: Australian waters, 890km West of Darwin
Project Completion: 15th May 2017

Project requirements

Sea Trucks Group required reinstatement and modification works on the Accommodation Modules that Specialist Services manufactured and delivered to them in 2014. We have been awarded this reinstatement and modification job based on the excellent work we did on the 2014 project with a fast track execution, including a production schedule of all 48 modules reduced to 16 weeks. The new Accommodation Block was required to be modified in order to provide Accommodation, Locker Room, Washroom, Toilet, Office, Recreation and Conference facilities, accommodating up to 224 personnel on board. The modules were required to be connected to form a block 11 modules wide and 4 modules high.

Within the requirement, the existing Mess Room needed to be converted to a Gymnasium, and the Locker Room and Dry Store to be converted into Recreation Rooms. STG also required communication system upgrades, HVAC improvements, door and panel modifications, installation review and supply of required consumables for the new stacking arrangement, and supply of all materials required to complete the upgrade. Electrical engineering / drawing updates and a module stacking study were also required by STG for this project.

Solution

The project execution by Specialist Services has been carried out in line with STG requirements at the site in Batam, converting the Mess Room into a Gymnasium, and the Locker Room and Dry Store into Recreation Rooms, as per the drawings provided by the client.

Specialist Services team also completed the A/C drainage system upgrade, electrical and Fire & Gas interconnection cabling works, the provision of an Electrical Distribution Panel for each floor, as well as the upgrade of the communication system, which included the relocation of patch panels from outside the module into its interior and mounting required infrastructure to allow the installation of existing switches within the modules.

A total of 44 modules were installed on the Barge, connecting the modules to each other in rows of 11 modules with 4 stacking. The resulting Accommodation Facility was built in compliance with ABS guides for Portable Accommodation Modules and MLC (Maritime Labour Convention 2013).

Conclusion

In line with the project requirements, we provided a highly skilled team of specialists from our Dubai facility to manage the project and carry out the reinstatement and modification works at the client’s venue of choice, a shipyard in Batam, Indonesia.

The project was successfully completed by Specialist Services within the specified timeframe. At the end of the project were issued as built drawings incorporating all the modification works, and Specialist Services supported STG with the documentation requirements for obtaining an updated ABS certification.

The high quality modifications, upgrades and reinstatement works provided by Specialist Services resulted in comfortable living and working environments. All works have been completed to a very high standard and STG Management was very satisfied with Specialist Services’ team performance.

ETR and ICR Buildings for Tecnicas Reunidas

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Specialist Services has successfully completed the ETR and ICR Buildings project awarded by Tecnicas Reunidas

Tecnicas Reunidas (TR) awarded Specialist Services the contract for the supply of an Electrical Technical Room (ETR) and an Instrument Control Room (ICR) to be used on the ADOC’s Hail Oil Field offshore Abu Dhabi.

Project: Supply of ETR and ICR buildings for Hail Oil Field Development Project
Client: Tecnicas Reunidas
End User: Abu Dhabi Oil Company – ADOC
Location: Hail Oil Field offshore Abu Dhabi
Project Completion: 17th April 2017
ETR dimensions: (L) 34 x (W) 11 x (H) 10.8 m
ICR dimensions: (L) 21 x (W) 8.3 x (H) 9.4 m

Project requirements

Abu Dhabi Oil Company (ADOC) intend to develop the Hail Oil Field located approximately 10km South of Mubarraz Island in the shallow water areas of the Arabian Gulf and 100km West of Abu Dhabi. This development aims to achieve a peak in oil production of 21,000 BPD from the Hail Oil Field. The oil shall be produced from the Thamama Zone A, B and F reservoirs and require some gas injection and gas lift for oil recovery. Tecnicas Reunidas (TR) had been awarded a project of the Hail Oil Field development Early Production Scheme (EPS) phase.

In order to facilitate the above, the prefabricated containerised type Electrical Technical Room (ETR) and Instrument Control Room (ICR) were required and TR awarded the project to Specialist Services. The scope of work included design, engineering, manufacturing, installation of equipment, interconnection cabling, inspection, testing, pre-commissioning, packing, shipping and supply of ETR and ICR buildings.

The buildings were required to be prefabricated, self-contained, skid-mounted, factory manufactured, completely assembled, wired and tested at the factory prior to being mobilised to the site. Other requirements included the provision of the HVAC system, for the buildings mounted on skids in non-hazardous areas, false floors, HSSD and NOVEC Firefighting systems, a minimum of 2 hours fire rating for external walls, roof, floor and doors, and also to be blast-resistant.

Solution

The ETR and ICR buildings have been designed, manufactured and supplied in line with ADOC’s requirements. At the beginning, our engineering team worked exceptionally hard to engineer the solutions that would satisfy client’s specifications, and additional design change requests from the client were also successfully implemented during project execution.

The structural design of the buildings was frozen by the end of October 2016. Detailed engineering and fabrication had to be done in tandem to complete the project on time, as required by the contractor at Hail Field. We timely achieved this through close cooperation with the contractor and third party inspectors.

The project was challenging due to the unusual completion schedule for both buildings: 22 weeks for ICR and 26 weeks for ETR. Specialist Services Mussafah yard team in Abu Dhabi worked tirelessly for three months to complete the project in this short lead time, demonstrating outstanding dedication and excellent work.

In-land transportation of ETR to Mussafah Port Jetty was a major challenge due to its width and height. However, Specialist Services, together with their transporter, managed the operation well with proper planning and utmost care. Prior permissions from Abu Dhabi Municipality, Road Transport, Traffic and Mussafah Port authorities were obtained for smooth operations.

Conclusion

The project required complex engineering, coordination and construction due to the specific requirements related with existing interfaces and characteristics of the Hail Oil Field Terminal. A number of specifications and design changes were requested by the client, which resulted in additional works.

The pre-commissioning of the installed systems lasted around 20 days under close vigilance and inspection by TR, Mott MacDonald (PMC) and ADOC staff deployed at the Specialist Services yard in Abu Dhabi.

After a successful site acceptance test of the ETR and ICR buildings by TR and ADOC, these heavy structures were weighed using hydraulic jacks & load cells arrangement at the Specialist Services yard in Abu Dhabi. ICR weighing operation was carried out on 13th April 2017 using 10 load cells, while ETR used 18 load cells on 16th April 2017. ICR and ETR weighed 114 Ton and 237 Ton respectively.

We completed the project and handed it over to TR at Mussafah Port Jetty, Abu Dhabi, on 16th and 17th April 2017 in line with the agreed completion schedule. Both buildings were transported to Mussafah Port with the help of SPMTs in-land transportation.